Apparatus for making a scrub puff



Dec. 2, 1969 P. 1.. BARNHOUSE APPARATUS FOR MAKING A SCRUB PUFF Original Filed Aug. 5, 1964 INVENTOR. P404 4. EAGMIOUJE United States Patent Int. Cl. A47l 13/20 U.S. Cl. 300-16 9 Claims ABSTRACT OF THE DISCLOSURE A method of making a scrub puff involves stacking layers of fabric, sewing the layers together longitudinally, cutting a length of the sewn layers, crumpling the fabric layers into the suitable shape and finally stapling the crumpled layers to form the puff. Apparatus for assisting in these operations is a fixture for spreading the layers.

CROSS REFERENCES This application is a division of my co-pending application Ser. No. 386,935 filed Aug. 3, 1964 for Scrub Puff, now Patent No. 3,343,196, issued Sept. 26], 1967.

BACKGROUND OF THE INVENTION The present invention relates generally to cleaning devices and more particularly to apparatus for and method of making a scrub puff from an open net fabric. Because of its novel construction, the scrub puff has an open or expanded construction and is, accordingly, referred to as a puff rather than a pad, although, as will be seen from the following description, the device is used manually in a manner similar to the usual scrub pad.

It is an object of the present invention to make by a novel sequence of operations performed both quickly and easily a scrub puff which has a lOng life so that its usefulness is not impaired by the characteristics which make it economical.

It is another object of the present invention to provide apparatus for forming a scrub pad or puff from a suitable material into a configuration such that the puff is easily rinsed out and kept free of particles of dirt that would be objectionable.

It is a still further object of the present invention to devise apparatus for and a method of making the scrub puff quickly, easily and economically by either hand or power operated procedures.

SUMMARY OF THE INVENTION The above and other objects and advantages of the present invention are attained by stacking together a plurality of layers of fabric which are then sewn together centrally and longitudinally, compressing the layers lengthwise to form random folds and fastening the folds together with suitable fastening means. This can be carried on as a continuous operation by feeding in continuously strips of fabric of greater length than desired and cutting off a length of the strips after the sewing operation, the cut length then being compressed to form random folds which are secured together to form the puff.

Apparatus for assisting in carrying on these operations involve a plurality of spaced, parallel rods arranged in a circular pattern for separating the layers of fabric which are located between successive rods, and support means for the rods comprising a pair of spaced support members outside of the rods and connected thereto by radial posts. A terminal section of the apparatus preferably is provided with rods of wavy configuration in order to facilitate formation of folds in the puff. A stapling head slidably mounted on a guide rod is movable into position to staple the compressed folds of fabric.

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BRIEF DESCRIPTION OF THE DRAWING How these and other objects and advantages of the present invention are achieved will be more readily understood by reference to the following description and to the annexed drawing, in which:

FIG. 1 is a schematic layout in perspective showing various steps involved in the making of the scrub puff embodying the present invention;

FIG. 2 is a vertical section on line 22 of FIG. 1;

FIG. 3 is a side elevation of a scrub puff embodying the present invention; and

FIG. 4 is an enlarged fragmentary view showing in plan a section of the type of open net preferably used in making the scrub puff.

DESCRIPTION OF PREFERRED EMBODIMENTS A preferred method of making a scrub pulf will now be described with reference to FIG. 1. The first operation is to stack on top of one another a plurality of layers 10 of a suitable fabric. These layers 10 are preferably in the form of comparatively narrow, elongated strips of fabric which are taken off of supply rolls, not shown in the drawing, and are then moved longitudinally into position one over another as shown in FIG. 1. The four strips shown in the drawing are typical of the number of layers of fabric utilized, but it will be realized that the invention is not limited to this number and that more or fewer layers may be used as desired.

The strips 10 are fed from right to left in the drawing past a sewing station where, by means of any suitable type of sewing machine, the plurality of layers are sewn together by a centrally located, longitudinally extending seam indicated at 12. Sewing the strips together holds them in position relative to each other against either lateral or longitudinal displacement and makes it possible to handle the multiple layers as a unit during the succeeding operations.

As shown in FIG. 1, the strips 10 are fed longitudinally while in a flat condition and this condition is maintained as they pass the sewing station. Thus, when the strips are sewn, they are lying one on top of another. The next operation is to separate and spread apart the layers. This is easily and efliciently accomplished with the aid of a suitable guide 15 comprising a pair of spaced rings 16 and 17 which act as supports for a plurality of longitudinally extending separators 18, which typically are smooth rods arranged in a circular pattern (FIG. 2). Rods 18 extend axially of and between rings 16 and 17 from which rods 18 are supported by short, radially inwardly extending posts 19. As the layers enter guide 15, they are not only separated but they are spread apart by rods 18 sufficiently that the several layers are placed in a generally cylindrical configuration during their passage from ring 16 to ring 17. This may be also seen in FIG. 2.

The procedure illustrated in FIG. 1 is designed to be a continuous method since such a method simplifies many of the operations in manufacture and results in greater economies. Each individual pufi' is made from a suitable length of the strips after they are sewn together; and this length can be estabished by feeding the end of the strips forwardly to one end of a second guide 20 which, like guide 15, is composed of a pair of spaced rings 21 and 22 which support an annular array of longitudinally extending rods 23 on radial posts 24. The length of guide 20 is preferably established to equal the desired length of --material to be gathered together to form a single puff. The two guides 15 and 20 are spaced apart sufliciently to allow the passage between them of suitable cutting means, not shown, thus establishing the cutting station at the beginning of guide 20 which defines the gathering section of the apparatus.

After the desired length of material is severed from the following strips 10, the leading end of the cut length is held stationary while the trailing end is then pushed forwardly, compressing the cut length endwise, or edgewise of the individual layers of fabric, producing in each of the layers random folds, as indicated generally at 25 in FIG. 1.

While rods 23 may be straight as are rods 18, it is preferred that they have a wavy conformation in the gathering section of the apparatus. This shape favors the formation of the multiple folds in the layers of fabric.

While holding the compressed length of material in the compact configuration, it may be removed from the end of guide 20 and transported to a station where suitable fastening means are applied to hold the folds permanently in that position. This fastening can be accomplished by any suitable means, but it is preferred that the fastening means be a single metallic staple 28, as indicated in FIG. 3. The staple is preferably made of a non-ferrous alloy so that there is no rusting after contact with water.

It is preferred to provide at the gathering section 20 stapling head 30 which is mounted slidably on guide bar 31. This bar may be mounted on rings 21 and 22 as shown or otherwise suitably supported to place the stapling head above the work. With this arrangement, the stapling head is moved downwardly as indicated by arrow 32 to a position at the end of the cut length of fabric. It is then advanced, pushing the fabric ahead of it as already described to compress the layers and form the puff. At the end of the travel, the head is actuated to place staple 28, after which the puff is removed from guide section 20 and the stapling head returned to its staring position. It is preferably movable relative to bar 31 to allow it to move into stapling position and then upwardly out of the way of the advancing fabric.

Feeding the strips through the various steps of the manufacturing operation can be accomplished by any suitable means. It is assumed in the foregoing description that the strips are fed manually and that the steps of compressing the material and removing it from the end guide are accomplished in a similar manner. However, it will be understood that the invention is not limited thereto and includes in its scope a completely mechanized operation in which all steps are carried out by power operated means.

The preferred type of fabric for making the puff is an open net material formed from one of the modern synthetic materials, as, for example, nylon. Suitable synthetic fibers are also made of polyesters, polyvinyls, or polyethylene, and other modern synthetic resins, commonly referred to as plastics. In general, these fibers have the desirable property of being non-absorbent since they are non-porous and impervious to moisture. Fibers of this character are often referred to as hydrophobic.

Such an open net material is also crisp and stiff so that after the folds 25 are gathered together and stapled, they extend radially outward from their comon fastening at 28, producing a generally rounded configuration or ball shape. Of course, because of the irregularities which are normal and inherent in the manufacture, the shape is not truly spherical but is instead irregular, and likewise varies from one puff to another so that they cannot be said to have a definitely uniform final shape. Fabrics of this type are not woven from twisted yarn but are made by other processes and typically appear to have a honeycomb construction, as shown in FIG. 4. The size of the openings between fibers is not critical and may differ with the overall size of the final puff, bigger openings being used with a bigger puff or heavier fibers.

It will be apparent from the foregoing that the method of making the puff illustrated herein is not limited to a continuous operation but that the puffs can be made individually by what may be termed a batch operation. The chief difference in this case would be that the cutting operation would take place earlier, as, for example, before the several layers are laid one on top of another or immediately after the sewing step.

From the foregoing description, it will be understood that various changes in the scrub puff constituting the present invention and 'the method of making it may be made without departing from the spirit and scope of the present invention. Accordingly, it is to be understood that the foregoing description is considered to be illustrative of, rather than limitative upon, the invention as defined by the appended claims.

I claim:

1. The method of making a scrub puff that includes the steps of:

stacking a plurality of layers of fabric;

sewing the layers together;

compressing the layers edgewise to form random folds;

and fastening the folds together.

2. The method of making a scrub puff as in claim 1 that includes:

separating and spreading apart the layers prior to compressing the layers.

3. The method of making a scrub puff as in claim 1 in which fastening the folds is done by stapling the folds.

4. The method of making a scrub puff as in claim 1 that also includes the steps of:

feeding continuous strips of fabric one over another into a predetermined position at which the sewing is done;

spreading the layers apart after the sewing steps;

cutting a length of the sewn strips;

and compressing the cut length endwise into random folds.

5. The method of making a scrub puff as in claim 4 in which the strips of fabric are fed and sewn in a Hat condition and are then spread apart into a generally cylindrical configuration.

6. Apparatus for forming a scrub puff from a plurality of superposed layers of fabric, comprising in combination:

a plurality of spaced, parallel rods arranged in a circular pattern for separating the layers of fabric;

and support means for said rods comprising a pair of spaced support members outside of said rods and connected thereto by radially extending posts, leaving the space inwardly of the rods free for passage of layers of fabric.

7. Apparatus as in claim 6 in which the parallel rods each have a wavy conformation.

8. Apparatus as in claim 6 which also includes:

a guide bar extending parallel to the rods and at one side thereof;

and a stapling head slidably mounted on the guide bar for movement parallel to said rods, said head being movable into and out of a position centrally of the circular pattern of said rods.

9. Apparatus as in claim 6 that also includes cutting means at one end of the plurality of parallel bars and operating transversely of the travel of said layers moving parallel to the bars, to cut a predetermined length of the fabric layers.

References Cited UNITED STATES PATENTS GRANVILLE Y1 CUSTER, JR., Primary Examiner 

